3D Printing of Flexible Polymers for Respiratory Protection

Department of Defense personnel must wear respiratory protection continuously when deployed in regions with the danger of chemical or biological attack. Manufacturing respirators/masks using conventional molding methods limits the features that can be designed into the protection. Additive manufacturing provides an ideal approach for manufacturing respirators. Additive Manufacturing enables the ability for 1) New features that cannot be achieved with molding processes, including better and more comfortable fit, 2) Modification to mask design without having to invest the time and funds in new molds, 3) Masks that are custom-fit to the facial structure of the end-user, and 4) the Ability to print multifunctional composite materials. Phase I demonstrated 3D printed flexible resins that exhibited compelling permeation resistance against chemical warfare agent simulants. In this Phase II SBIR, Actuated Medical, Inc. (AMI), an ISO 13485-Certified (FDA GMP Compliant) Medical Device Developer and Manufacturer, will finalize and commercialize 3D Printing of Flexible Polymers for Respiratory Protection. The flexible polymers will find additional use in 3D printing of medical devices and masks for first-responders.